Construction panels, materials, systems, and methods

ABSTRACT

Construction panels and other materials, methods for their manufacture, and systems and methods for monitoring environmental conditions with such panels are provided herein. The panels include a core having a first surface and an opposed second surface, and an environmental sensor assembly associated with the panel and configured to detect an environmental condition of the panel and wirelessly communicate data on the environmental condition to a reader.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. application Ser. No.15/455,795, filed Mar. 10, 2017, which claims priority benefit of U.S.Provisional Application No. 62/306,995, filed on Mar. 11, 2016, thedisclosures of which are incorporated by reference herein.

FIELD

The present disclosure relates generally to the field of panels andother materials for use in building construction, and more particularlyto panels and other construction materials with environmental sensors,methods of making such panels, and systems for their use.

BACKGROUND

Interior wallboard, exterior building sheathing, flooring, roofing, andother building panels can be exposed to extreme environmental conditionsincluding moisture, wind, and extreme temperatures during and afterconstruction. Additionally, such systems may be installed improperly,such that seams between panels are not completely sealed. Furthermore,sheathing and roofing panels installed around windows, scuppers, parapetwalls, and other openings and areas in the building may be particularlyvulnerable to environmental damage.

When moisture intrusion and/or degradation or destruction of the panelsoccurs due to these conditions, it often goes unnoticed for a length oftime, usually until visually observed. Moreover, leaks and/ordegradation that may not be visible via typical inspection methods maynever be detected. Thus, such damage conditions, as well as mold andmildew resulting from water infiltration, may intensify to easilyavoidable levels because of the lack of early detection systems forthese issues.

For example, in environments exposed to freezing temperatures, waterleaking into a roofing or sheathing panel may undergo multiplefreeze-thaw cycles and thereby cause separation of the panel core andthe fiberglass mat facer and associated membrane (e.g., building wrap),if present. Once separation of the mat facer has occurred, winduplifting causes further separation of the mat facer, sometimesresulting in billowing of the mat facer.

Accordingly, it would be desirable to provide construction panels andother construction materials having sensors for detecting environmentalconditions in or on the panel/structure, to monitor and prevent damageto such materials.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the drawings, which are meant to be exemplary and notlimiting, and wherein like elements are numbered alike. The detaileddescription is set forth with reference to the accompanying drawingsillustrating examples of the disclosure, in which use of the samereference numerals indicates similar or identical items. Certainembodiments of the present disclosure may include elements, components,and/or configurations other than those illustrated in the drawings, andsome of the elements, components, and/or configurations illustrated inthe drawings may not be present in certain embodiments.

FIG. 1 is a diagrammatic, fragmentary side elevational view illustratingportions of a manufacturing line for producing gypsum board of a typesuitable for use in the manufacture of gypsum panels prepared for use inaccordance with the present disclosure;

FIG. 2 is an enlarged fragmentary sectional view, taken as indicatedtoward the left of FIG. 1, of an underlying fiber glass mat used in themanufacture of the gypsum board;

FIG. 3 is a fragmentary plan view taken as indicated by the line 3-3 onFIG. 2;

FIG. 4 is an enlarged sectional view taken as indicated toward the righton FIG. 1 and illustrating both underlying and overlying fiber glassmats, with intervening gypsum composition, used in the manufacture ofthe board;

FIG. 5 is a fragmentary plan view taken as indicated by line 5-5 on FIG.4;

FIG. 6 is a fragmentary bottom view taken as indicated by the line 6-6on FIG. 4 and illustrating the bottom surface of the underlying mat ofthe board;

FIG. 7 is a transverse sectional view of an edge portion of thecompleted board, this view being taken as indicated by the line 7-7 onFIG. 4;

FIG. 8 is a further enlarged fragmentary sectional view taken asindicated toward the top of FIG. 4;

FIG. 9 is a further enlarged fragmentary sectional view taken asindicated toward the bottom of FIG. 4;

FIG. 10 is a perspective view partly broken away and in section of anexemplary roof deck system incorporating a panel in accordance with thepresent disclosure;

FIG. 11 is an enlarged sectional view taken along line 11-11 of FIG. 10;

FIG. 12 is a greatly enlarged sectional view of the circled area of FIG.11 showing the penetration of the first asphalt layer into the fibrousupper surface of the panel in accordance with the disclosure;

FIG. 13 is a perspective view of another type of roof systemincorporating the panel in accordance with the disclosure as the primarysupport layer;

FIG. 14 is a sectional view taken along line 14-14 of FIG. 13;

FIG. 15 is a perspective view partly broken away and in section of acomposite wall structure employing the panel in accordance with thedisclosure;

FIG. 16 is a greatly enlarged view of the circled portion of FIG. 15showing the penetration of the plaster layer into the fibrous surface ofthe panel;

FIG. 17 is a cross-sectional view of a construction panel;

FIG. 18 is a cross-sectional view of a construction panel;

FIG. 19 is a perspective view of a building sheathing system havingwater-resistive and air-barrier properties;

FIG. 20 is a plan view of an environmental sensor assembly;

FIG. 21 is a perspective view of a roof deck assembly;

FIG. 22 is a partial perspective view of a roof deck assembly;

FIG. 23 is a cross-sectional view of a construction panel or material;and

FIG. 24 is a cross-sectional view of a flooring underlayment.

DETAILED DESCRIPTION

Disclosed herein are building construction panels and materials, as wellas methods of making such panels and materials, and systems for theiruse. The panels and materials described herein may be panels forinternal or external construction applications, such as for wallboard,external sheathing, roof board, and flooring, sound mitigation and rainscreen mats, and other construction applications. For example, thepanels described herein may be external gypsum sheathing panels, such asthose described in U.S. application Ser. Nos. 15/014,793 and 15/014,922,entitled “Gypsum Panels, Systems, and Methods,” which are incorporatedherein by reference in their entirety. For example, the panels describedherein may be fiber-reinforced gypsum panels containing cellulosicfibrous material, such as those described in U.S. Pat. Nos. 6,893,752,8,070,895, 6,342,284, 6,632,550, 7,244,304, 7,425,236, 7,758,980,7,964,034, 8,142,914, and 8,500,904, which are incorporated by referenceherein in their entirety. For example, the panels described herein maybe roof deck panels, such as those described in U.S. Pat. No. 5,319,900,which is incorporated by reference herein in its entirety. For example,the panels described herein may be isocyanurate or similar insulationtype panels, such as those described in U.S. Pat. No. 7,612,120, whichis incorporated by reference herein in its entirety. For example, thepanels described herein may be plywood, oriented strand board (OSB), orother wood-based panels known in the construction industries. Forexample, the construction materials described herein may be polymericrain screen or sound mitigation mats, such as those described in U.S.Pat. Nos. 9,157,231 and 7,861,488, which are incorporated by referenceherein in their entirety. For example, the panels or constructionmaterials described herein may be gypsum and/or concrete flooringunderlayments, such as those described in U.S. Pat. No. 7,651,564, whichis incorporated by reference herein in its entirety. Overall, thisdisclosure is directed to various construction panels and materials forinternal and/or external construction applications, for commercialand/or residential applications, in which the construction panels and/ormaterials contain environmental sensors configured for detecting one ormore environmental conditions of the panel, material, or surroundingstructure with which it is associated.

Construction Panels and Materials

Generally, the panels and other construction materials may include anysuitable construction or configuration known in the industry. Forexample, the panels may be panels that contain gypsum as a significantcomponent of the panel core (e.g., in amounts of up to 90 percent, byweight, or more) or may be panels that contain gypsum as a component ofthe panel core in combination with other components (e.g., in amounts ofless than 90 percent). Examples of other components that may be presentin the panel core include cellulose or other fibers. Furthermore, whilethe present disclosure is generally directed to building panels thatinclude a gypsum core or layer, other panels may be suitably substitutedfor the gypsum panel, such as wood-based, foam-based, and othermaterial-based panels that are suitable for the building constructionpurposes described herein. That is, while various embodiments of thepresent disclosure are described or illustrated with reference to agypsum panel, it should be understood that the gypsum core and otherpanel features could be replaced with suitable components of these otherpanel or construction material types. In particular, such panels andother materials are described in the documents incorporated by referenceherein. For example, these panels and mats may include any suitablepanel core (e.g., one or more layers forming the structural core of thepanel) along with any suitable facer material or other external coatingmaterial, as will be described herein.

In certain embodiments, as shown in FIG. 23, a building panel 2300includes a panel (e.g., a panel core 2301 formed of a one or more layersof a panel core material 2308, with or without a facer material) havinga first surface 2307 and an opposed second surface 2309, and anenvironmental sensor assembly 2320, 2322, 2324 associated with the panel2300 and configured to detect an environmental condition of the panel2300 and wirelessly communicate data on the environmental condition to areader, wherein the environmental sensor assembly is self-supporting andcomprises an antenna, a processing module, and a wireless communicationmodule. For example, as discussed above, the panel may be selected froma gypsum panel, a fiber-reinforced gypsum panel, an isocyanurate panel,a wood-based panel, or other known construction panels. For example, aconstruction material may also be provided, such as various constructionmats or other structures including, but not limited to, a polymeric rainscreen, a polymeric sound mitigation mat, and a polymeric roofingdrainage mat, having an environmental sensor assembly associatedtherewith. For example, such mats may be rolled materials that are cutto size as needed. As shown in FIG. 23, the environmental sensorassembly (various assemblies illustrated, shown as 2320, 2322, 2324) maybe positioned in or on any suitable surface (internal or external) ofthe panel or material. For example, the environmental sensor assemblymay be disposed on an external surface or edge of the panel or within oron a surface of the panel. For example, in panels having a facermaterial, a panel coating, or multiple layers forming the panel core,the environmental sensor assembly may be disposed internally, i.e.,between two layers of the panel.

For example, in a gypsum panel, such as a fiber-reinforced gypsum panel,the environmental sensor assembly may be disposed on an external surfaceor edge of the panel or within or on a surface of the panel. Forexample, in gypsum panels having a facer material, a panel coating, ormultiple layers forming the panel core, the environmental sensorassembly may be disposed internally, i.e., between two layers of thepanel. For example, in isocyanurate panels, the environmental sensorassembly may be disposed on an external surface or edge of the panel orwithin, such as between various layers of, or on a surface of the panel.For example, in wood-based panels, the environmental sensor assembly maybe disposed on an external surface or edge of the panel or within, suchas between various layers of, or on a surface of the panel. For example,in a polymeric mat, such as a sound mitigation mat, roofing drainagemat, or rain screen, the environmental sensor assembly may be disposedon an external surface or between various layers of the mat.

In certain embodiments, as shown in FIG. 24, a flooring underlayment2400 is provided, and includes a gypsum and/or concrete underlaymentmaterial 2401 (e.g., a pour-in-place or other suitable underlaymentmaterial configuration formed of one or more layers of underlaymentmaterial 2408 on a floor substrate 2430) and an environmental sensorassembly 2420, 2422, 2424 associated with the underlayment material andconfigured to detect an environmental condition of the underlayment andwirelessly communicate data on the environmental condition to a reader,wherein the environmental sensor assembly is self-supporting andcomprises an antenna, a processing module, and a wireless communicationmodule. For example, the underlayment may have a first surface 2407 andan opposed second surface 2409. For example, the environmental sensorassembly 2420, 2422, 2424 may be disposed within or on a surface of thegypsum and/or concrete underlayment material.

In certain embodiments, as shown in FIG. 17, a panel 1000 includes apanel core 101 having a first surface and a second opposed surface, anda first facer material 104 associated with the first surface of thepanel core 101. For example, the facer material may be any suitablefacer material known in the art, including paper and fibrous facermaterials. In certain embodiments, as shown in FIG. 17, the facermaterial 104 is a fibrous material, such as fiberglass. Thus, whilecertain embodiments herein are described with reference to a fiberglassmat, it should be understood that any suitable paper facer or otherfibrous mat material may be substituted and fall within the scope of thedisclosure.

In certain embodiments, as shown in FIG. 17, a gypsum panel 1000includes a gypsum core 101 having a first surface and a second opposedsurface, and a first facer material 104 associated with the firstsurface of the gypsum core 101. For example, the facer material may beany suitable facer material known in the art, including paper andfibrous facer materials. In certain embodiments, as shown in FIG. 17,the facer material 104 is a fibrous material, such as fiberglass. Thus,while certain embodiments herein are described with reference to afiberglass mat, it should be understood that any suitable paper facer orother fibrous mat material may be substituted and fall within the scopeof the disclosure.

In certain embodiments, the facer material is a nonwoven fibrous matformed of fiber material that is capable of forming a strong bond withthe material of a building panel core through a mechanical-likeinterlocking between the interstices of the fibrous mat and portions ofthe core material. Examples of fiber materials for use in the nonwovenmats include mineral-type materials such as glass fibers, syntheticresin fibers, and mixtures or blends thereof. Both chopped strands andcontinuous strands may be used.

In certain embodiments, the facer material is a nonwoven fiberglass mat.For example, the glass fibers may have an average diameter of from about1 to about 17 microns and an average length of from about 1/16 inch toabout 1 inch. For example, the glass fibers may have an average diameterof 13 microns (i.e., K fibers) and an average length of ¾ inch. Incertain embodiments, the non-woven fiberglass mats have a basis weightof from about 1.5 pounds to about 4.0 pounds per 100 square feet of themat. The mats may each have a thickness of from about 10 mils to about50 mils. The fibers may be bonded together to form a unitary matstructure by a suitable adhesive. For example, the adhesive may be aurea-formaldehyde resin adhesive, optionally modified with athermoplastic extender or cross-linker, such as an acrylic cross-linker,or an acrylate adhesive resin.

In certain embodiments, as shown in FIGS. 2 and 3, facer material mats 6and 16, contain glass fiber filaments 30 oriented in random pattern andbound together with a resin binder (not shown). One embodiment of glassfiber mat-faced gypsum board 40 is shown in FIGS. 4 and 7, in which theset gypsum of the core 42 penetrates substantially through the thicknessof the mat 6 over substantial area portions thereof and in which the setgypsum of the core 42 penetrates the mat 16 partially, with the surfacebeing thus substantially free of set gypsum. The gypsum-free surface ofmat 16, as seen in FIG. 8, is highly textured, and provides an excellentsubstrate for adhering thereto an overlying component inasmuch as itcontains many interstices into which an adhesive composition can flowand bond.

In certain embodiments, the panels have a thickness from about ¼ inch toabout 1 inch. For example, the panels may have a thickness of from about½ inch to about ⅝ inch.

In some embodiments, as shown in FIG. 17, gypsum crystals of the gypsumcore 101 penetrate a remaining portion of the first fiberglass mat 104such that voids in the first fiberglass mat 104 are substantiallyeliminated and the water resistance of the panel 1000 is furtherenhanced. For example, in one embodiment, the first fiberglass mat 104has a continuous barrier coating 106 on a surface opposite the gypsumcore 101, the continuous barrier coating 106 penetrating a portion ofthe first fiberglass mat 104, to define the remaining portion of thefirst fiberglass mat 104. That is, gypsum crystals of the gypsum core101 penetrate a remaining fibrous portion of the first fiberglass mat104 such that voids in the first fiberglass mat 104 are substantiallyeliminated. As used herein the phrase “such that voids in the fiberglassmat are substantially eliminated” and similar phrases refer to thegypsum slurry (e.g., slate coat) filling all or nearly all of theinterstitial volume of the fiberglass mat that is not filled by thecoating material.

As used herein, the term “continuous barrier coating” refers to acoating material that is substantially uninterrupted over the surface ofthe fibrous mat. The continuous barrier coating on the external surfaceof the facer may be any suitable coating known in the art. For example,the coating may include a binder material and, optionally, a filler. Forexample, the coating may include a polymer or resin based bindermaterial along with one or more inorganic fillers.

In certain embodiments, as shown in FIG. 17, the gypsum core 101includes two or more gypsum layers 102, 108, while in other embodimentsthe gypsum core includes a single gypsum layer. For example, the gypsumcore may include various gypsum layers having different compositions. Insome embodiments, the first gypsum layer 102 that is in contact with thefiberglass mat 104 (i.e., the layer that forms an interface with thecoating material and at least partially penetrates the remaining fibrousportion of the first fibrous mat) is a slate coat layer. In someembodiments, the first gypsum layer 102 is present in an amount fromabout 2 percent to about 20 percent, by weight, of the gypsum core 101.The various gypsum layers are shown as separate layers in the figuresfor ease of illustration; however, it should be understood that overlapof these materials may occur at their interfaces.

The layers of the gypsum core may be similar to gypsum cores used inother gypsum products, such as gypsum wallboard, drywall, gypsum board,gypsum lath, and gypsum sheathing. For example, the gypsum core may beformed by mixing water with powdered anhydrous calcium sulfate orcalcium sulfate hemihydrate, also known as calcined gypsum, to form anaqueous gypsum slurry, and thereafter allowing the slurry mixture tohydrate or set into calcium sulfate dihydrate, a relatively hardmaterial. In certain embodiments, the gypsum core includes about 80weight percent or above of set gypsum (i.e., fully hydrated calciumsulfate). For example, the gypsum core may include about 85 weightpercent set gypsum. In some embodiments, the gypsum core includes about95 weight percent set gypsum. The gypsum core may also include a varietyof additives, such as accelerators, set retarders, foaming agents, anddispersing agents.

In certain embodiments, as shown in FIG. 18, a gypsum panel 200 includestwo facers 204, 212 that are associated with the gypsum core 201. Aswith the first facer material, the second facer material may be anysuitable facer material, such as paper or fibrous materials. In certainembodiments, both facers 204, 212 are fiberglass mats. The secondfiberglass mat 212 is present on a face of the gypsum core 201 oppositethe first fiberglass mat 204. In some embodiments, only the firstfiberglass mat 204 has a continuous barrier coating 206 on a surfacethereof. In other embodiments, both fiberglass mats 204, 212 have acoating 206, 214 on a surface thereof opposite the gypsum core 201. Insome embodiments, the gypsum core 201 includes three gypsum layers 202,208, 210. One or both of the gypsum layers 202, 210 that are in contactwith the fiberglass mats 204, 212 may be a slate coat layer.

As shown in FIG. 17, gypsum panels according to the present disclosuremay have a first surface 107 of the panel 1000 formed by the first facermaterial 104 and/or a continuous barrier coating 106 thereon. The gypsumpanel 1000 also has a second surface 109 of the panel opposite the firstsurface 107.

In certain embodiments, as shown in FIGS. 10-14 and 21-22, the panel maybe a roof deck panel. For example, installation of a roof deck system inconstruction of a building, generally involves constructing a frame forsupport of the roof of a building; affixing to the frame corrugatedsheets to provide a surface for support of the other components of theroof deck system; affixing to the corrugated sheets planar supportmembers; and affixing to the planar support members an exteriorfinishing material having good weathering properties. Roof deck systemswhich include panels of insulation sandwiched between the aforementionedcorrugated sheets and planar support members are used widely also. Suchsystems are designed to be insulative in character and weatherresistant. Such roof deck systems can be used to advantage to conserveenergy used for heating and to conserve energy used forair-conditioning. More specifically, such roof deck systems typicallyinclude corrugated metal sheets which are mechanically affixed, usuallyby screws or bolts, to appropriate structural members of the buildingsuch as steel beams. The corrugated metal sheets support the weight ofthe components which overlie it, including the insulating material (whenused), the planar support members, and the finishing material. Lightweight, low density insulating panels such as expanded polystyrene,polyisocyanurate, and the like, are used widely in such systems,especially in colder climates. The planar support members generallyinclude gypsum boards and are fastened in place by mechanical fastenerssuch as screws to the underlying corrugated metal sheet. When panels ofinsulation are used, they are sandwiched between the underlyingcorrugated metal sheets and the overlying panels of gypsum board. Anexterior finishing material, such as a polymeric or rubber membrane oralternating layers of asphalt and roofing felt, overlies the panels ofgypsum board.

A typical roof deck system incorporating the fibrous mat-faced gypsumboard as described above is shown in FIGS. 10 to 12. In thisconstruction, spaced parallel trusses 50 extending between buildingsupport members (not shown) support a corrugated metal deck 52 which iswelded or otherwise fastened to the trusses. Layers 54 and 56 ofinsulating sheet material, which may, for example, be ofpolyisocyanurate, are disposed on the corrugated metal deck. A layer 58of fibrous mat-faced gypsum board panels of the type described hereaboveare secured to the corrugated deck 52 by means of fasteners 60 passingtherethrough and through the underlying insulation layers 54 and 56 intothe deck 52. The joints of the panel layer 58 are sealed by applicationof tape 62, as shown in FIG. 10 with respect to one of the panel joints.Overlying the gypsum layer 58 is a waterproof roofing membrane includingalternate layers of asphalt 64 and roofing felt 66, three layers of eachbeing shown in the present example. A final coating of asphalt 68 iscovered with a crushed gravel topping layer 70.

In the enlarged view of FIG. 12, the manner in which the first asphaltlayer 64 penetrates into the upwardly facing fibrous mat-face of thegypsum board panel layer 58 is illustrated. This penetration assures asecure adhesion of the waterproof membrane to the structural layers ofthe roof system.

In some embodiments, as shown in FIG. 21, the roof deck system 150incorporating the gypsum panels having the environmental sensor assemblyincludes a gypsum roof board/panel, as an overlayment 158, underlayment154, or both, as well as insulation 156, and a roof covering or membrane160, mounted on a steel, wood, or other roof deck 152 (shown as steel).In some embodiments, as shown in FIG. 22, the roof deck system 162incorporating the gypsum panels having the environmental sensor assemblyis a single-ply membrane system. For example, the system may include atleast one gypsum roof panel 166, 170, insulation 168, and a single-plymembrane 172 (e.g., EPDM or thermoplastic membrane). Various embodimentsof such roofing systems utilizing gypsum roofing panels are known in theart and the present disclosure is meant to encompass any such suitablesystem configurations or designs incorporating the gypsum panelsdisclosed herein. For example, the roofing system may incorporatesuitable asphalt, EPDM, Turbo Seal, CSPE, Modified Bitumen, PVC, coldliquid membranes, FTPO, TPO, coal-tar pitch built up, or other built uproof constructions, among others.

Referring to FIGS. 13 and 14, a poured-in-place roof deck system isshown including purlins 72 supporting spaced sub-purlins (bulb tees 74in parallel spaced relation). Fibrous mat-faced gypsum board panels 76of the type described above are supported on the horizontal flanges 74 aof the sub-purlins 74. A reinforcing mesh screen 78 is laid over thesub-purlins and gypsum board panels 76 and a layer of settable gypsumslurry 80 is poured in place over the reinforcing mesh. The slurry 80 isallowed to harden to form a smooth continuous deck surface 82. Adhesionof the slurry to the gypsum board panel 76 is assured by the penetrationof the slurry into the upwardly facing fibrous mat surface of thepanels. A roofing membrane including alternate layers of asphalt 84 androofing felt 86, three layers of each in the illustrated example, isapplied to the surface 82. A final layer of asphalt 88 is covered with acoating of crushed rock or gravel 90.

As regards interior finishing systems for use in a building,installation of such a system generally involves constructing a framefor support of the interior walls of a building; and affixing to theframe planar support members which provide a smooth continuous surfaceto support an interior finishing material having aesthetic anddurability properties. Such systems are designed to be strong anddurable and to withstand abuse during the building's occupancy. Anexample of an interior usage of the present fibrous mat-faced panel isillustrated in FIGS. 15 and 16. In these views, an interior wall systemincludes spaced vertical studs 92 to which fibrous mat-faced gypsumboard panels 94 are attached by spaced fasteners 96 such as screws ornails. A thin layer 98 of plaster is applied to the fibrous mat surface100 of the panel 94 and is troweled to form a smooth finish surfacewhich may then be decorated by paint, paper or the like in aconventional manner. As shown in the enlarged view of FIG. 16, theplaster 98 penetrates into the fibrous mat surface of the panel 94 toeffect a secure mechanical bond of the plaster layer to the panel.Although shown in the context of a wall in FIG. 15, the panel 94 mayequally suitably be used as a ceiling panel and can be used with eithera wood or metal stud support system. For some applications, it may befound that adjustments need to be made in the water-resistant propertiesof the core in order to obtain a satisfactory plaster finish.

In exterior systems, sheathing panels can be affixed to an underlyingsupport member in any suitable way, for example, by the use of nails orscrews. In such systems, the underlying support member may include, forexample, panels of rigid plastic or metal sheets, for example, incorrugated form, purlins and sub-purlins. Panels of insulating materialmay be affixed to such support members and underlie panels of saidpanels, which are affixed thereto. The support member is typicallyaffixed to the frame of the building.

In certain embodiments, as shown in FIGS. 17 and 18, the gypsum panelincludes at least one environmental sensor assembly 120, 122, 124associated with the gypsum panel. Although three environmental sensorassemblies are shown in FIGS. 17 and 18, it should be understood that asensor assembly may alternatively be provided at one, two, or each ofthese locations, as well as at other locations in and on the gypsumpanel.

In one embodiment, the environmental sensor assembly 120 is disposed onthe first surface of the panel. In one embodiment, the environmentalsensor assembly 122 is disposed on the second surface of the panel. Forexample, the first surface of the panel may be the external-facingsurface of the panel upon installation, while the second surface of thepanel may be the internal-facing surface of the panel upon installation.In other embodiments, the environmental sensor assembly is disposed atan external edge of the panel. In other embodiments, the environmentalsensor assembly 124 is disposed within or at a surface of the panelcore. For example, the environmental sensor assembly may be positionedon or adjacent the facer material or in another portion of the corematerial of the panel core, such as in the slate coat or another of thegypsum layers in a gypsum panel. In other embodiments, the environmentalsensor assembly may be disposed on the surface of the facer materialthat receives a continuous barrier coating. Thus, the environmentalsensor assembly may be disposed at any suitable position on or in thepanel, depending on the desired location and type of environmentalcondition detection and the particular application of the panel.

In certain embodiments, the environmental sensor assembly is configuredto detect an environmental condition of the panel or material with whichit is associated and to communicate data regarding the environmentalcondition to a reader. For example, the environmental sensor assemblyconfigured to detect one or more environmental conditions such asmoisture, temperature, and/or pressure.

In certain embodiments, the environmental sensor assembly isself-supporting and includes a substrate on which an antenna, aprocessing module, and a wireless communication module are disposed. Asused herein, the term “self-supporting” refers to the sensor assemblybeing operable to sense the target environmental conditions as astandalone assembly, without the need for a wired connection external tothe sensor assembly. As such, the environmental sensor assembliesdisclosed herein may advantageously be incorporated into panels or othermaterials at a variety of positions throughout the panel duringmanufacturing or at a construction site, without the need for additionallabor or materials to wire or programs the sensors. In certainembodiments, the environmental sensor assembly is a passive system. Asused herein, the term “passive system” refers to the sensor assemblyhaving no battery and instead using the radio energy transmitted by areader to power the assembly. Advantageously, passive systems may beused in applications where the panels, materials, and/or sensorassemblies are largely inaccessible, making replacement of the assemblyor a battery associated therewith impossible without damaging thebuilding or building envelope. Moreover, because passive systems have nopower source and often no moving parts, these assemblies may have anextremely long lifespan that is at least equal to the typical lifespanof panels or other construction materials. In other embodiments, theenvironmental sensor assembly is an active system that includes anintegrated power source, such as a battery, for example a rechargeablebattery, such as one powered by solar power.

In certain embodiments, the environmental sensor assembly is a passive,ultra high frequency single-chip sensor inlay system. In certainembodiments, the antenna is a resistor/inductor/capacitor (RLC) tunedcircuit operable to convert the environmental condition into animpedance change, and the processing module is coupled to the antennaand is operable to translate the impedance change into a sensor code bymatching antenna impedance to die impedance. Thus, whereas traditionalsensors exploit changes in resistance to measure environmentalvariables, which results in reduced tag read range due to powerdissipated in the resistance, the present sensor assemblies' ability touse inductance or capacitance beneficially avoids issues with readrange.

For example, the antenna may have an antenna impedance operable to varybased on the environmental condition. The processing module may becoupled to the antenna and include a tuning module operable to (i) varya reactive component impedance in order to change a system impedanceincluding the antenna impedance and the reactive component impedance,and (ii) produce an impedance value representative of the reactivecomponent impedance. The wireless communication module may be coupled tothe processing module and operable to communicate the impedance valuerepresentative of the reactive component impedance to the reader, whichrepresents the data on the environmental condition. In some embodiments,the environmental sensor assembly also includes a memory module operableto store the impedance value representative of the reactive componentimpedance.

For example, the sensor assembly may be a passive radio frequencyidentification (RFID) sensor, such as the sensor described in PCTApplication Publication No. WO2015/184460, which is incorporated byreference in its entirety herein. As shown in FIG. 20, this passive RFIDsensor includes an antenna, a processing module, and a wirelesscommunication module. The antenna has an antenna impedance that may varywith the environment in which the antenna is placed. The processingmodule couples to the antenna and has a tuning module that may vary areactive component impedance coupled to the antenna in order to change asystem impedance that includes both the antenna impedance and thereactive component impedance. The tuning module then produces animpedance value representative of the reactive component impedance. Amemory module may store the impedance value which may then later becommunicated to an RFID reader via the wireless communication module.The RFID reader may then exchange the impedance value representative ofthe reactive components of impedance with the RFID reader such that theRFID reader or another external processing unit may process theimpedance value in order to determine environmental conditions at theantenna.

FIG. 20 is a view of one embodiment of an RFID moisture or humiditysensing tag 3300. Moisture or humidity sensing tag 3300 is a passiveRFID tag having a substrate 2101, on which is disposed an integratedcircuit (IC) 2100. IC 2100 includes a memory module 2012, a wirelesscommunication engine 2104, and a sensor engine 2106, which includes anantenna. IC 2100 is capable of sensing a change in the environmentalperimeters proximate to IC 2100 via impedance changes associated withthe antenna. Memory module 2102 is coupled with both the wirelesscommunication engine 2104 and the sensor engine 2106. Memory module 2102is capable of storing information and data gathered by sensor engine2106 and communicated via wireless communication engine 2104. Further,wireless communication engine 2104 and sensor engine 2106 may be fullyprogrammable via wireless methods.

The sensor impedance varies as the coupling of interdigitated capacitor3304 responds to environmental changes. In one embodiment,interdigitated capacitor 3304 is located proximate to a film 3306applied above interdigitated capacitor 3304. Film 3306 may be a materialhaving an affinity for water (i.e., moisture or humidity) or otherfluids, such as CO, CO₂, Arsenic, H₂S or other known toxins or gases ofinterest. When film 3306 absorbs a fluid such as those describedpreviously, the dielectric constant proximate to the interdigitatedcapacitor 3304 changes causing an impedance change. The impedance of theinterdigitated capacitor 3304 sensed by the processing module coupled tothe sensor then produces an output, a sensor code, representative of theabsorbed material within film 3306. This data may be stored within amemory circuit of IC 2100 or transmitted to an external reader by thewireless communication module of IC 2100.

Thus, in certain embodiments, when configured as a moisture sensor, thesensor assembly measures the presence of water when the surroundingenvironment becomes wet. The interdigitated capacitor experiences asignificant change in capacitance, when it changes from dry to wet; thedipole antenna registers an impedance change depending on the amount ofwater on the capacitor; and the sensor IC converts this into a code thatindicates the amount of water present.

Advantageously, the sensor assemblies described herein may have a smallsize, such as approximately 4 inches by 1 inch, and be very thin, so asto provide nominal additional thickness when applied externally to thepanel or construction material.

Methods

Methods of manufacturing construction panels and materials describedherein are also provided. For example, a gypsum panel, fiber-reinforcedgypsum panel, isocyanurate panel, polymeric rain screen, polymeric soundmitigation mat, polymeric roofing drainage mat, wood-based panel, aflooring underlayment, or other construction material may bemanufactured through any suitable means known in these industries. Forexample, as described above, the environmental sensor assembly may beassociated with the panel, material, or underlayment during or after themanufacturing process. For example, the environmental sensor assemblymay be embedded within a material forming of the panel or othermaterial, or may be disposed between various layers (e.g., layersforming a panel core, facer, and/or coating) of the panel or material.

For example, in a gypsum panel, the environmental sensor assembly may beassociated with the panel prior to or after setting of the gypsum core.In certain embodiments, the environmental sensor assembly is positionedin the gypsum slurry, for example at, near, or distal from the facermaterial, prior to setting. In other embodiments, the environmentalsensor assembly is attached or affixed to an external surface or edge ofthe gypsum panel. In other embodiments, the environmental sensorassembly is attached or affixed to a surface of the facer materialopposite the gypsum core and covered by, embedded in, or surrounded by acoating material. In other embodiments, the environmental sensorassembly is attached or affixed between the facer material and thegypsum core.

Alternatively, as discussed above with reference to FIGS. 13 and 14, apoured-in-place gypsum or concrete panel system may be used for roofingor flooring underlayment applications, wherein the environmental sensorassembly is applied during the pour-in-place process.

In some embodiments, the environmental sensor assembly is appliedin-line with the panel manufacturing process. In other embodiments, theenvironmental sensor assembly is applied post-panel manufacturing, suchas at a construction site or intermediate storage or othermanufacturing/processing facility.

Methods of making gypsum panels having water-resistive properties arealso provided. In certain embodiments, during manufacturing, a gypsumslurry may be deposited on the uncoated surface of the facer materialand set to form a gypsum core of the panel. Where the facer material isa fibrous mat, the gypsum slurry may penetrate some remaining fibrousportion of the thickness of the mat (i.e., some portion of the mat thatis not already penetrated by the coating) and provide a mechanical bondfor the panel. The gypsum slurry may be provided in one or more layers,having the same or different compositions, including one or more slatecoat layers. As used herein, the term “slate coat” refers to a gypsumslurry having a higher wet density than the remainder of the gypsumslurry that forms the gypsum core. These methods may be used to producegypsum panels having any of the features, or combinations of features,described herein. Enhanced penetration of the gypsum into the fibrousmat may be achieved by chemical modification of the gypsum slurry, byapplication of a penetration-enhancing coating on the surface of thefibrous mat contacted by the gypsum slurry, and/or by mechanical means.

In certain embodiments, the external surface of the fibrous mat iscoated with a continuous barrier coating that penetrates a portion ofthe first fiberglass mat, to define the remaining portion of the firstfiberglass mat that gypsum crystals of the gypsum core penetrate, suchthat voids in the first fiberglass mat are substantially eliminated.

In certain embodiments, the gypsum core includes multiple layers thatare sequentially applied to the fiberglass mat, and allowed to seteither sequentially or simultaneously. In other embodiments, the gypsumcore includes a single layer. In some embodiments, a second fiberglassmat may be deposited onto a surface of the final gypsum slurry layer (orthe sole gypsum slurry layer), to form a dual mat-faced gypsum panel.For example, the first and/or second fiberglass mat may include abarrier coating on its surface that penetrates a portion of the mat. Thegypsum slurry or multiple layers thereof may be deposited on thefiberglass mat by any suitable means, such as roll coating.

In some embodiments, the gypsum core includes at least three gypsumlayers, with the outermost gypsum layers of the gypsum core (i.e., thelayers that form an interface with the fiberglass mats). In certainembodiments, both outermost layers are chemically altered for enhancedpenetration.

In certain embodiments, the first and/or second fibrous mats are alreadycoated upon contacting the gypsum (or other panel core) slurry. In someembodiments, the methods include applying the continuous coating to thefirst and/or second fibrous mat, either before or after contacting themats with the panel core slurry. In certain embodiments, applying thebarrier coating includes spray coating, ribbon coating, curtain coating,knife coating, or direct roll coating. In some embodiments, the barriercoating is applied to each of the first and/or second fibrous mats in anamount from about 1 pound to about 9 pounds, per 100 ft². For example,the barrier coating may be applied to the first and/or second fibrousmat in an amount from about 2 pounds to about 8 pounds, per 100 ft². Inother embodiments, coated fibrous mats may be obtained in apre-fabricated form.

In some embodiments, the method also includes mechanically vibrating atleast the first fiberglass mat having the first gypsum slurry depositedthereon to effect penetration of the gypsum slurry into the remainingfibrous portion of the first fiberglass mat.

In certain embodiments, the panel core slurry (or layers thereof) may bedeposited on the non-coated side of a horizontally oriented moving webof pre-coated fibrous mat. A second coated or uncoated fibrous mat maybe deposited onto the surface of the panel core slurry opposite thefirst coated fibrous mat, e.g., a non-coated surface of the secondcoated fibrous mat contacts the panel core slurry. In some embodiments,a moving web of a pre-coated or uncoated nonwoven fibrous mat may beplaced on the upper free surface of the aqueous panel core slurry. Thus,the panel core material may be sandwiched between two fibrous mats, oneor both having a barrier coating. In certain embodiments, allowing thepanel core material and/or continuous barrier coating to set includescuring, drying, such as in an oven or by another suitable dryingmechanism, or allowing the material(s) to set at room temperature (i.e.,to self-harden).

In certain embodiments, as shown in FIGS. 1 to 9, dry ingredients (notshown) from which the gypsum core is formed are pre-mixed and then fedto a mixer of the type commonly referred to as a pin mixer 2. Water andother liquid constituents (not shown) used in making the core aremetered into the pin mixer 2 where they are combined with the dryingredients to form an aqueous gypsum slurry. The slurry 4 is dispersedthrough one or more outlets at the bottom of the mixer 2 onto a movingsheet of fibrous mat 6. The sheet of fibrous mat 6 is indefinite inlength and is fed from a roll (not shown) of the mat. In certainembodiments, the two opposite edge portions of the fibrous mat 6 areprogressively flexed upwardly from the mean plane of the mat 6 and thenturned inwardly at the margins so as to provide coverings for the edgesof the resulting board 40. In FIG. 1, this progressive flexing andshaping of the edges of the mat 6 are shown for only one side edge ofthe mat and the conventional guiding devices which are ordinarilyemployed for this purpose are omitted from the figure for the sake ofclarity. FIG. 7 shows an edge of the set gypsum core 42 covered by theoverlapped edge portion 6A of the mat 6. FIG. 7 shows also score marks10 and 10A of the mat 6, the score marks permitting the formation ofgood edges and flat surfaces. The score marks 10 and 10A are made by aconventional scoring wheel 12. An advantage of using the glass fiber matis that it is capable of being scored and edged like conventional paperfacing.

Another sheet of fibrous mat 16 is fed from a roll (not shown) onto thetop of slurry 4, thereby sandwiching the slurry between the two movingfibrous mats which form the slurry. The mats 6 and 16 with the slurry 4sandwiched therebetween enter the nip between the upper and lowerforming or shaping rolls 18 and 20, and are thereafter received on aconveyer belt 22. Conventional edge guiding devices, such as indicatedat 24, shape and maintain the edges of the composite until the gypsumhas set sufficiently to retain its shape. In due course, sequentiallengths of the board are cut and further processed by exposure to heatwhich accelerates the drying of the board by increasing the rate ofevaporation of excess water in the gypsum slurry.

With reference to FIG. 7, it has been observed that the set gypsum ofthe core 42 is effective in forming satisfactory bonds with the mats andbetween the edge portions of the overlying mat 16 and the overlappededge portion 6A of the underlying mat 6, thus making it unnecessary touse a bond improver in the slurry or an edge paste to form theaforementioned bonds.

In certain embodiments, the method of making the panel includesassociating a self-supporting environmental sensor assembly with thepanel. For example, the environmental sensor assembly may be anysuitable assembly described herein, such as those including an antenna,a processing module, and a wireless communication module, and configuredto detect an environmental condition of the panel and wirelesslycommunicate data on the environmental condition to a reader.

Applications

Systems and methods for detecting an environmental condition at a panelor other construction material are also provided herein. In certainembodiments, a system includes at least one of the building panels,materials, or flooring underlayments described herein along with atleast one reader for receiving the data wirelessly communicated from theenvironmental sensor assembly. In certain embodiments, a system includesat least one panel containing an environmental sensor assembly, such asare described herein, and at least one reader for receiving the datawirelessly communicated from the environmental sensor assembly. Incertain embodiments, a method of monitoring an environmental conditionof a panel includes providing at least one panel having an environmentalsensor assembly associated therewith, detecting an environmentalcondition of the panel, via the environmental sensor assembly, andwirelessly communicating data on the environmental condition from theenvironmental sensor assembly to a reader.

The reader may be any suitable wireless sensor reader known in the art.For example, the reader may be a handheld manual reader. In otherembodiments, the reader is a stationary powered reader mounted at abuilding containing the at least one panel, material, or underlayment.For example, at a building containing one or more panels havingenvironmental sensor assemblies installed as roof deck,interior/exterior sheathing panels, mats, or other structural panels, apowered reader may be mounted at one or more sites on and/or around thebuilding to continuously or intermittently monitor the status of theenvironmental sensor assemblies. In certain embodiments, a buildingcontrol system is provided to receive information from the reader(s). Insome embodiments, a reader may be mounted on a drone that is configuredto approach the at least one panel to receive the data wirelesslycommunicated from the environmental sensor assembly. In certainembodiments, the sensing data is digitized and wirelessly communicatedto off-the-shelf readers using a standard UHF Gen 2 protocol READcommand for further processing.

In certain embodiments, the system also includes a processing unit andthe reader is configured to communicate the data on the environmentalcondition to the processing unit, and the processing unit is operable todetermine at least one condition status at the environmental sensorassembly from the data. For example, the reader may be configured tocommunicate the impedance value representative of the reactive componentimpedance to the processing unit, such that the processing unit isoperable to determine at least one condition status at the environmentalsensor assembly from the impedance value representative of the reactivecomponent impedance.

In certain embodiments, the system includes an integration service thatallows for programming of the sensors without requiring complex ITinfrastructure and middleware. For example, the integration service mayprovide for a repository of all sensor tag-related data, e.g. sensorrange and calibration data, that can be accessed securely by authorizedweb services and apps, a repository of measurement data related to thesensor-tagged panels, and a decision flow engine, e.g. so that if ansensor-tagged panel exceeds a preset level (e.g., a preset moisturelevel), a notification is sent by SMS/email to a service technician.

In certain embodiments, raw data is collected from these sensors via thereader for processing to be performed by a data processing unit wherecomputation occurs to determine a humidity or temperature measurement.Further, with reference to FIG. 20, wireless communication engine 2104and sensor engine 2106 may be fully programmable via wireless methods.Passive RFID sensors of FIG. 20 may be deployed as an array of smartsensors (e.g., multiple sensor assemblies on one or multiple panelsinstalled at a single site) to collect data that may be sent back to acentral processing unit. Another embodiment provides an environmentalsensing method for use in an RF system including the steps of:calibrating an RF sensor by developing a first calibration valueindicative of an absence of a detectable quantity of a substance and asecond calibration value indicative of a presence of the detectablequantity of the substance, installing the sensor in a structure,exposing the structure to the substance, interrogating the sensor toretrieve a sensed value, and detecting the presence of the substance inthe structure as a function of the sensed value relative to the firstand second calibration values.

As shown in FIG. 19, a building may include a sheathing system includingat least two panels 300 and a seaming component 320 configured toprovide a seam at an interface between at least two of the panels 300.Environmental sensor assemblies 350, 352 may be provided on or in one ormore internal wallboard, external sheathing, or roof panels, asdescribed herein. In particular, such panels having environmental sensorassemblies may be useful in sheathing or roofing systems in whichimproved water resistance is desired, so that water infiltration may bedetected quickly and efficiently.

In certain embodiments, the seaming component in such systems includestape or a bonding material. For example, the seaming component may be atape including solvent acrylic adhesives, a tape having a polyethylenetop layer with butyl rubber adhesive, a tape having an aluminum foil toplayer with butyl rubber adhesive, a tape having an EPDM top layer withbutyl rubber adhesive, a tape having a polyethylene top layer withrubberized asphalt adhesive, or a tape having an aluminum foil top layerwith rubberized asphalt adhesive. For example, the seaming component maybe a bonding material such as synthetic stucco plasters, cementplasters, synthetic acrylics, sand filled acrylics, solvent basedacrylics, solvent based butyls, polysulfides, polyurethanes, silicones,silyl modified polymers, water-based latexes, EVA latexes, or acryliclatexes. Thus, the above-described panels may be installed with either atape, liquid polymer, or other suitable material, to effectively treatareas of potential water and air intrusion, such as seams, door/windowopenings, penetrations, roof/wall interfaces, and wall/foundationinterfaces. As such, the building sheathing panels, when used incombination with a suitable seaming component, may create an effectivewater-resistive and/or air-barrier envelope.

Thus, in certain embodiments, the building construction panels,materials, and underlayments described herein are configured to detectmoisture, temperature, or pressure on roofs, on other exterior buildingcomponents, on exterior building components covered with a membrane ofother covering, within roofs or walls, and within the building envelope.The system is configured to detect environmental conditions that couldlead to the deterioration of roof systems or other building components.Thus, the systems described herein may advantageously provide earlydetection of moisture intrusion prior to damaging the roof, flooring,walls, or other regions of the building system.

Instead of the traditional manual inspections of roofing and/or otherpanels, the use of the readers described herein will reduce or eliminatethe labor associated with inspections. The readers could be handheld orcould be attached to a drone which would transport a reader from tag totag (i.e., sensor assembly to sensor assembly). Alternately, the readerwould be a powered reader, such as those used in highway and DOTapplications, mounted on a roof or other location that reads the tagsand relays the information over the internet or similar system to asmart building control system. In addition to external sheathing androofing applications, the panels and sensors could also be used in theinterior of the building, to identify moisture intrusion anywhere in thebuilding, including mold and mildew resistant basement applications,behind shower and tile board, and/or on or behind exterior sheathing.

Moreover, the present panels eliminate the need for wired sensors andsensors containing a microcontroller, in which the labor involved inprogramming and installation is very high. In these wired embodiments, atechnician having microcontroller/PLC programming knowledge would haveto program the system to operate. The present system will be virtuallyplug-and-play, and any programming may be done before panel installationin the form of a GUI (graphical user interface) that will integrate withexisting facility management software. In systems having a stationaryreader(s), such as commercial buildings, the reader advantageously mayby connected to the building network and maintained by a buildingengineer along with other facility systems (e.g., HVAC, firesuppression, lighting, occupancy control).

While the disclosure has been described with reference to a number ofembodiments, it will be understood by those skilled in the art that theinvention is not limited to such disclosed embodiments. Rather, theinvention can be modified to incorporate any number of variations,alterations, substitutions, or equivalent arrangements not describedherein, but which are commensurate with the spirit and scope of theinvention. Additionally, while various embodiments of the invention havebeen described, it is to be understood that aspects of the invention mayinclude only some of the described embodiments. Accordingly, theinvention is not to be seen as limited by the foregoing description, butis only limited by the scope of the appended claims.

What is claimed is:
 1. A building panel, comprising: a panel having afirst surface and an opposed second surface; and an environmental sensorassembly associated with the panel and configured to detect anenvironmental condition of the panel and wirelessly communicate data onthe environmental condition to a reader, wherein the environmentalsensor assembly is self-supporting and comprises an antenna, aprocessing module, and a wireless communication module.
 2. The panel ofclaim 1, wherein the environmental sensor assembly is configured todetect an environmental condition of the panel selected from a groupconsisting of moisture, temperature, and pressure.
 3. The panel of claim1, wherein the environmental sensor assembly comprises a passive radiofrequency identification sensor.
 4. The panel of claim 1, wherein: theantenna comprises a resistor inductor capacitor tuned circuit operableto convert the environmental condition into an impedance change, and theprocessing module is coupled to the antenna and is operable to translatethe impedance change into a sensor code by matching antenna impedance todie impedance.
 5. The panel of claim 1, wherein: the antenna has anantenna impedance operable to vary based on the environmental condition,the processing module is coupled to the antenna and comprises a tuningmodule operable to (i) vary a reactive component impedance in order tochange a system impedance comprising the antenna impedance and thereactive component impedance, and (ii) produce an impedance valuerepresentative of the reactive component impedance, the wirelesscommunication module is coupled to the processing module and is operableto communicate the impedance value representative of the reactivecomponent impedance to the reader, and the data on the environmentalcondition comprises the impedance value representative of the reactivecomponent impedance.
 6. The panel of claim 5, wherein the environmentalsensor assembly further comprises a memory module operable to store theimpedance value representative of the reactive component impedance. 7.The panel of claim 1, wherein the panel is selected from a gypsum panel,a fiber-reinforced gypsum panel, an isocyanurate panel, and a wood-basedpanel.
 8. The panel of claim 1, wherein the environmental sensorassembly is disposed on an external surface or edge of the panel orwithin or on a surface of the panel.
 9. The panel of claim 1, whereinthe panel comprises: a panel core; and a facer material.
 10. A systemfor detecting an environmental condition at a panel, comprising: atleast one of the building panels of claim 1; and at least one reader forreceiving the data wirelessly communicated from the environmental sensorassembly.
 11. The system of claim 10, further comprising a processingunit, wherein the reader is configured to communicate the data on theenvironmental condition to the processing unit, and the processing unitis operable to determine at least one condition status at theenvironmental sensor assembly from the data.
 12. The system of claim 10,wherein the at least one reader comprises a powered reader mounted at abuilding containing the at least one building panel.
 13. The system ofclaim 12, further comprising a building control system configured toreceive information from the powered reader.
 14. The system of claim 10,wherein the at least one reader comprises a handheld manual reader. 15.A flooring underlayment, comprising: a gypsum and/or concreteunderlayment material; and an environmental sensor assembly associatedwith the underlayment material and configured to detect an environmentalcondition of the underlayment and wirelessly communicate data on theenvironmental condition to a reader, wherein the environmental sensorassembly is self-supporting and comprises an antenna, a processingmodule, and a wireless communication module.
 16. The underlayment ofclaim 15, wherein the environmental sensor assembly is configured todetect an environmental condition of the panel selected from a groupconsisting of moisture, temperature, and pressure.
 17. The underlaymentof claim 15, wherein the environmental sensor assembly comprises apassive radio frequency identification sensor.
 18. The underlayment ofclaim 15, wherein: the antenna comprises a resistor inductor capacitortuned circuit operable to convert the environmental condition into animpedance change, and the processing module is coupled to the antennaand is operable to translate the impedance change into a sensor code bymatching antenna impedance to die impedance.
 19. The underlayment ofclaim 15, wherein: the antenna has an antenna impedance operable to varybased on the environmental condition, the processing module is coupledto the antenna and comprises a tuning module operable to (i) vary areactive component impedance in order to change a system impedancecomprising the antenna impedance and the reactive component impedance,and (ii) produce an impedance value representative of the reactivecomponent impedance, the wireless communication module is coupled to theprocessing module and is operable to communicate the impedance valuerepresentative of the reactive component impedance to the reader, andthe data on the environmental condition comprises the impedance valuerepresentative of the reactive component impedance.
 20. The underlaymentof claim 19, wherein the environmental sensor assembly further comprisesa memory module operable to store the impedance value representative ofthe reactive component impedance.
 21. The underlayment of claim 15,wherein the environmental sensor assembly is disposed within or on asurface of the gypsum and/or concrete underlayment material.